FOOD SAFETY ENGINEERING AND MANAGEMENT
SAFWAN’S CURRIE PARADISE FOOD SAFETY SCENARIO
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The aim of the module is to introduce a range of traditional and emerging technologies employed to ensure the safety of food. It explores a range of current food related safety issues, including the analysis of risk and reviews current hygiene practices in the food industry.
This will be done via the exploration of a case study, “the Safwan’s Currie Paradise Safety Senario” which will require you apply the theoretical and technical apects of food safety management to a “real life” scenario from a technical managment perspective.
The module will also examine the implementation, auditing and evaluation of appropriate processes and procedures/controls to effect safe processing of foods and aims to provide students with the necessary skills to enable students to synthesise and critically appraise different aspects of food safety technologies and food safety management in complex contexts.
A series of milestone online tutorial activities and Webinars, running on an interactive basis, will facilitate the use of the Safwan’s Currie Paradise Safety Senario case study and problem-solving exercises. Students will receive formative feedback from the submission of on line exercises and online tests based on the case study.
Introduction
The “Safwan’s Currie Paradise Safety Scenario” will require you apply the theoretical and technical aspects of food safety management to a “real life” scenario from a technical manger perspective.
You have been employed by the Managing Director of a company, that has just taken over ownership of a manufacturer of ready to eat and ready to cook meals, based on Indian and far eastern recipes.
The Mission Statement of Safwan’s Currie Paradise is;
“Authentic Halal Meals with that home cooked taste. With traditional recipes based on the meals grandma used to make, you can be sure to get at taste of home away from home. Our Halal meals are made strictly in accordance with Sharia Law and our Ethnic vegetarian meals made separately so as to satisfy all religious denominations.”
The factory currently manufactures a range of dishes including; Butter Chicken, Chicken Balti, Chicken Tikka, Madras Fish Curry, Prawns in a butter-tomato sauce, boiled rice, pilau rice, vegetable pilau, Bombay potatoes, Tadka Dal, Coconut Dal and Tomato and onion cachumbar
Since establishment over 10 years ago, they have built solid customer relationships and now have a reputation as the number one supplier of Halal and Ethnic food to the public sector in the North of England UK.
You have been employed to develop effective food safety systems for the company to ensure the future safe production of food.
As part of the internal investigation the new owners of the company has carried out a preliminary audit, which has revealed that the basic state of hygiene in the factory leaves much to be desired. This includes, among other things:
- Poor standards of stock control/stock rotation,
- Inadequate control over cooking/heating processes,
- Inadequate control of food prepared in advance.
- Lack of physical contamination controls.
- Inadequate control of preparation and cooling of prepared and part prepared dishes
- inadequate maintenance controls
- A general lack of temperature control
Staff Resources
The company employs the following staff;
- Managing Director
- Finance Manager
- Sales Manager
- Operations Manager
- Transport Manager
- 2 Supervisors (2 shifts)
- 24 Production staff
- 4 Hygienists/Cleaners
- 8 Drivers
- 2 Sales Staff
- 2 Telesales operators
- 1 Handyman
FACTORY DESIGN & OPERATION
Factory Design & Layout
The factory has the following design and layout.
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OUTLINE PRODUCTION METHOD
Basic Sauce
The basic sauce is used in some of the other recipes in Safwan’s Curry Paradise. This is stored in the chiller freezer for up to one week.
| Ingredients | Preparation & Cooking |
| · vegetable oil
· Pre – weighed onion – finely chopped · Pre – weighed cloves garlic – peeled and sliced · Pre – weighed root ginger – peeled and thinly sliced · Pre – weighed mild fleshy green chillies – de-seeded and veined then chopped · Pre – weighed turmeric powder · Pre – weighed ground cumin seed · Pre – weighed ground coriander seed · Pre – weighed smooth sieved tomatoes |
Heat the oil in a brat pan then add the chopped onion and stir for a few minutes.
Add the ginger, garlic and green chilli. Cook for 15 minutes stirring from time to time. Add the turmeric, cumin and coriander and cook, still very gently, for a further 5 minutes. Add pureed tomatoes and cook for further 10 minutes over very low heat stirring occasionally. Add a little water if the sauce as necessary. Decant from brat pan in to trays & rack Cool using blast chiller to below 5°C Place in Pre-preparation walk in chiller
|
Chicken Balti
| Ingredients | Preparation & Cooking |
| · vegetable oil
· Pre – weighed red and green sweet pepper – cut into half-inch squares · Pre – weighed medium onion sliced · Pre – weighed red and green chillies – de-seeded then coarsely chopped. · Pre – weighed whole cumin seeds · Pre – weighed chicken breasts, skinned and cut into bite-sized pieces · Pre – weighed good paprika · Pre – weighed turmeric · Pre – weighed ground cinnamon · Pre – weighed Basic Curry Sauce (see separate recipe) · Pre – weighed salt · Pre – weighed Garam masala |
Heat a little of the oil in a wok pan
Add the chicken pieces and stir-fry until they are sealed and have turned white. Remove the chicken from the pan and set aside. Add the onion, chopped chillies and cumin seeds and stir fry until the onion is translucent but not brown Add the peppers and stir-fry until they go a little brown at the edges. Add the paprika, turmeric and cinnamon Add the Basic Curry sauce, tomato purée and salt. Cook for 20 minutes or until the chicken is cooked. Add a little hot water if the sauce gets too thick. 10 minutes from the end add the Garam masala into the sauce. Decant from pan in to trays & rack Cool using blast chiller to below 5°C Place in Pre-preparation walk in chiller |
PILAU RICE
Traditional rice dish, which accompanies chicken. It is also used with a range of other dishes.
Ingredients
Method
| Ingredients | Preparation & Cooking |
| · Pre – weighed basmati rice
· Pre – weighed unsalted butter · Pre – weighed onion finely chopped · Pre – weighed cloves garlic, peeled and finely chopped · Pre – weighed green cardamoms, split open the top of each pod · Pre – weighed cinnamon sticks, 2-inches long each, broken p · Pre – weighed whole peppercorns · Pre – weighed tsp ground turmeric · Pre – weighed water · Pre – weighed salt |
Wash the rice and soak in cold water for ½ an hour. Drain well.
In a heavy based pan melt the ghee or butter over medium heat and fry onions until they are soft but not brown (about 5 minutes). Add the garlic, cloves, cardamoms, cinnamon sticks and peppercorns. Stir and fry until the onions are golden brown (3-4 minutes). Add the rice and turmeric, stir and fry for 1-2 minutes. Adjust heat to low, stir and fry the rice for a further 2-3 minutes. Add the water and the salt, bring to the boil, cover and simmer for 15 minutes without lifting the lid. Remove the pan from the heat and keep it undisturbed for a further 10-12 minutes. Decant from brat pan in to trays & rack Place in Pre-preparation walk in chiller |
TADKA DAL
Traditional dish, utilising tempered spices along with pulses in a vegetarian dish.
Ingredients
Method
| Ingredients | Preparation & Cooking |
| For Dal
· Pre – weighed whole black lentils · Red kidney beans · Yellow split peas · Onions · Garlic cloves · Ginger · Green chillies · Tomato puree · Salt · For Tadka tempering · Cooking oil · Ghee · Cumin seeds · Cardamom pods · Cinnamon stick · Cloves · Peprcorns · Turmeric · Coriander · Fenugreek
· Double cream |
Wash the pulses and soak in cold water for 8 hours.
Drain and cover with fresh water. Cook slowly for 3 hours Puree onions, garlic, ginger, tomato puree and chillies into a paste. Heat oil and ghee Fry whole spices gently for 2 minutes. Add paste, fry for 5 minutes. Add powdered spices and cook for further 5 minutes. Add cream and heat gently for 2 minutes Decant from pan in to trays & rack Cool using blast chiller to below 5°C Place in Pre-preparation walk in chiller |
PRODUCT – Butter Chicken
Description
Cook Chilled Chicken Balti with Pilau Rice.
5 Day post production shelf life (Estimated)
Distribution via chill chain to Convenience Stores, catering outlets and workplace canteen chilled food dispensers
| Ingredients | Preparation & Cooking |
| For the marinade
· Pre-weighed plain yoghurt · Pre-weighed lime, juice only · Pre-weighed garlic, crushed · Pre-weighed fresh root ginger, grated · Pre-weighed ground cumin · Pre-weighed ground coriander · Pre-weighed garam masala · Pre-weighed paprika · Pre-weighed salt For the chicken · Pre-weighed chicken breasts · Pre-weighed Unsalted butter, melted · Pre-weighed lemon juice For the sauce · Double cream · salt · black pepper |
· Mix the marinade ingredients together in a bowl.
· Add chicken breasts and cover with marinade. · Place in the refrigerator for 12 hours. · Remove chicken, skewer and grill on high heat for 4 minutes, until the coating is golden-brown. · Coat chicken breasts with the butter and a little lemon juice. · Place skewers in oven and cook at 200C for 12 minutes. · Add basic sauce · Reduce heat, add cream and simmer for one minute. · Add chicken breasts with salt and black pepper. Decant from pan in to trays & rack Cool using blast chiller to below 5°C Place in Pre-preparation walk in chiller |
Cooking Instructions (to be printed on product sleeve)
For best results cook from frozen.
Appliances may vary, the following is a guide only.
| MICROWAVE | 700W | 900W |
| 1. Remove sleeve and pierce film lid. | – | – |
| 2. Heat on FULL POWER for: | 5 mins | 4 mins |
| 3. Gently shake pack and heat on FULL POWER for a further: | 5 mins | 4 mins |
| 4. Leave to stand in the microwave for: | 1 min | 1 min |
| 5. Remove film lid and serve. | – | – |
CONVENTIONAL OVEN
Pre-heat oven to 200ºC/400ºF, Gas Mark 6.
Remove sleeve, pierce film lid, place on baking tray.
Cook in the centre of the oven for 35-40 minutes (fan ovens may vary)
Remove film lid and serve.
Raw Ingredient Suppliers
| Supplier | Ingredient | Frequency of Delivery | Supplier Specification | Third Part Accreditation |
| Ollies Oil | vegetable oil
Ghee |
Monthly
|
Yes | Yes |
| Daves Veg | onion
mild fleshy green chillies smooth sieved tomatoes red and green sweet pepper |
Three time per week | Yes | No |
| Ali’s Wholesale | cloves garlic
cinnamon sticks green cardamoms root ginger |
Weekly | Yes | No |
| Spice online.com | turmeric powder
ground cumin seed ground coriander seed & powder whole cumin seeds |
Monthly | Yes | Yes |
| Kashmir Cash and Carry | frozen chicken breasts skinned and cut into bite-sized pieces
Tomato puree Roast Chicken Stock Single Cream Basmati Rice |
Twice Weekly
(Collected) |
No | No |
| Kashmir Cash and Carry | paprika
turmeric ground cinnamon dried curry leaves salt sugar garam masala |
Weekly
(Collected) |
No | No |
| Northumbria Water | Water |
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